Metal single layer abrasive cutting tool having a contoured cutting surface

Abstract

This invention relates to an abrasive cutting tool comprising: i) a substrate surface having a plurality of teeth extending therefrom, and ii) a single layer of abrasive grains chemically bonded to at least a portion of each tooth to define a plurality of cutting levels parallel to the substrate surface, the cutting levels comprising a first uppermost cutting level and a second uppermost cutting level, the grains having a predetermined concentration, size and toughness, whereby the abrasive cutting tool has a cutting surface with a negative angle of inclination with respect to an intended direction of cutting.

1. An abrasive cutting tool comprising:
 a) a monolithic substrate having a substrate surface with a plurality of teeth extending therefrom, each tooth having a contoured surface,  
 b) a layer comprising superabasive grains, the layer being chemically bonded to at least a portion of the surface of each tooth to define a plurality of cutting levels parallel to the substrate surface, and each cutting level on each tooth being oriented such that a portion of each cutting level overlaps at least a portion of each other cutting level of the tooth; and  
 c) a first uppermost cutting level consisting of bonded superabrasive grains, and successive uppermost cutting levels, comprising bonded superabrasive grains and a portion of the tooth, among the plurality of cutting levels of each tooth;  
 
     whereby after the first uppermost cutting level has been worn away by cutting a workpiece, each successive uppermost cutting level of the tooth presents to the workpiece a ring of superabrasive grain around the contoured surface of the tooth, and substantially all superabrasive grain within the ring simultaneously engages in cutting; 
     and wherein the substrate surface has an intended direction of movement and wherein the plurality of teeth includes successive teeth having successively lower uppermost cutting levels in the direction of the intended direction of movement, thereby producing a cutting surface having a negative angle of inclination with respect to the intended direction of movement. 
   
   
     2. An abrasive cutting tool comprising:
 a) a substrate surface having a plurality of teeth extending therefrom, each tooth having a surface and  
 b) a layer comprising abrasive grains, the layer being chemically bonded to at least a portion of the surface of each tooth to define a plurality of cutting levels parallel to the substrate surface,  
 
     wherein the substrate surface has an intended direction of movement, wherein the plurality of teeth includes successive teeth having successively lower uppermost cutting levels in the direction of the intended direction of movement, thereby producing a cutting surface having a negative angle of inclination with respect to the intended direction of movement.